Maintenance Definition

Maintenance is a set of organised activities that are

carried out in order to keep an item in its best
operational condition with minimum cost acquired.
 Maintenance Activities

Activities of maintenance function could be either

repair or replacement activities, which are necessary
for an item to reach its acceptable productivity
condition and these activities, should be carried out
with a minimum possible cost.
 Maintenance Objectives
The relation between maintenance objectives and
production goals is reflected in the action of keeping
production machines and facilities in the best possible
condition.
 Maximising production or increasing facilities
availability at the lowest cost and at the highest
quality and safety standards.
• Reducing breakdowns and emergency shutdowns.
• Optimising resources utilisation.
• Reducing downtime.
• Improving spares stock control.
• Improving equipment efficiency
• Minimising energy usage.
• Optimising the useful life of equipment.
• Providing reliable cost and budgetary control.
• Identifying and implementing cost reductions.
 PLANT

Maximising Production Reduce Breakdowns

M
A
Minimising Energy I Reduce Downtime
Usage N
T
Optimising Useful Life Improving Equipment
of Equipment
E Efficiency
N
Providing Budgetary A Improving Inventory
Control N Control
C
Optimising Resources E Implementing Cost
Utilisation Reduction

Figure:- Maintenance Objectives

 TYPES OF MAINTENANCE

• Run to Failure Maintenance (RTF)

• Preventive Maintenance (PM)

• Corrective Maintenance (CM)

• Improvement Maintenance (IM)

• Predictive Maintenance (PDM)

 Run to Failure Maintenance (RTF)

• The required repair, replacement, or restore action

performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.

• It is the oldest type of maintenance.

• It is subdivided into two types:
– Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
– Breakdown maintenance: it is performed after
the occurrence of an advanced considered failure
for which advanced provision has been made in
the form of repair method, spares, materials,
labour and equipment.
• Disadvantages:

1. Its activities are expensive in terms of both direct

and indirect cost.

2. Using this type of maintenance, the occurrence of a

failure in a component can cause failures in other
components in the same equipment, which leads to
low production availability.

3. Its activities are very difficult to plan and schedule

in advance.
 This type of maintenance is useful in the following
situations:

1. The failure of a component in a system is

unpredictable.

2. The cost of performing run to failure maintenance

activities is lower than performing other activities
of other types of maintenance.

3. The equipment failure priority is too low in order to

include the activities of preventing it within the
planned maintenance budget.
 Preventive Maintenance (PM)

It is a set of activities that are performed on plant

equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions.
The advantage of applying preventive maintenance
activities is to satisfy most of maintenance
objectives.
 The factors that affect the efficiency of this type of
maintenance:
1. The need for an adequate number of staff in the
maintenance department in order to perform this
type of maintenance.
2. The right choice of production equipment and
machinery that is suitable for the working
environment and that can tolerate the workload of
this environment.
3. The required staff qualifications and skills, which
can be gained through training.
4. The support and commitment from executive
management to the PM programme.
5. The proper planning and scheduling of PM
programme.
6. The ability to properly apply the PM programme.
 Preventive Maintenance (PM)
• It is good for those machines and facilities which
their failure would cause serious production losses.

• Its aim is to maintain machines and facilities in

such a condition that breakdowns and emergency
repairs are minimised.

• Its activities include replacements, adjustments,

major overhauls, inspections and lubrications.
 Researchers subdivided preventive maintenance
into different kinds according to the nature of its
activities:

• Routine maintenance which includes those

maintenance activities that are repetitive and
periodic in nature such as lubrication, cleaning, and
small adjustment.

• Running maintenance which includes those

maintenance activities that are carried out while the
machine or equipment is running and they represent
those activities that are performed before the actual
preventive maintenance activities take place.
• Opportunity maintenance which is a set of
maintenance activities that are performed on a
machine or a facility when an unplanned
opportunity exists during the period of performing
planned maintenance activities to other machines or
facilities.

• Window maintenance which is a set of activities

that are carried out when a machine or equipment is
not required for a definite period of time.

• Shutdown preventive maintenance, which is a set of

preventive maintenance activities that are carried
out when the production line is in total stoppage
situation.
 Corrective Maintenance (CM)
• In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.

The maintenance carried out after recognition and

intended to put an item into a state in which it can
perform a required function.
 This type of maintenance is subdivided into three
types:

• Remedial maintenance, which is a set of activities

that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.

The way to carry out this type of corrective

maintenance is by taking the item to be corrected
out of the production line and replacing it with
reconditioned item or transferring its workload to
its redundancy.
• Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.

• Shutdown corrective maintenance, which is a set of

corrective maintenance activities that are performed
when the production line is in total stoppage
situation.
• The main objectives of corrective maintenance are
the maximisation of the effectiveness of all critical
plant systems, the elimination of breakdowns, the
elimination of unnecessary repair, and the reduction
of the deviations from optimum operating
conditions.

• The difference between corrective maintenance

and preventive maintenance is that for the
corrective maintenance, the failure should occur
before any corrective action is taken.

• Corrective maintenance is different from run to

failure maintenance in that its activities are
planned and regularly taken out to keep plant’s
machines and equipment in optimum operating
condition.
 The way to perform corrective maintenance
activities is by conducting four important steps:

1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.

In the fault elimination step several actions could be

taken such as adjusting, aligning, calibrating,
reworking, removing, replacing or renovation.
 Corrective maintenance has several prerequisites in
order to be carried out effectively:

1. Accurate identification of incipient problems.

2. Effective planning which depends on the skills of
the planners, the availability of well developed
maintenance database about standard time to repair,
a complete repair procedures, and the required
labour skills, specific tools, parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
 Improvement Maintenance (IM)
• It aims at reducing or eliminating entirely the need for
maintenance.
• This type of maintenance is subdivided into three types as
follows:

1. Design-out maintenance which is a set of activities that

are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.
2. Engineering services which includes construction and
construction modification, removal and installation, and
rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of

improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.
 Predictive Maintenance (PDM)
• Predictive maintenance is a set of activities that
detect changes in the physical condition of
equipment (signs of failure) in order to carry out the
appropriate maintenance work for maximising the
service life of equipment without increasing the risk
of failure.

• It is classified into two kinds according to the

methods of detecting the signs of failure:
– Condition-based predictive maintenance
– Statistical-based predictive maintenance
• Condition-based predictive maintenance depends
on continuous or periodic condition monitoring
equipment to detect the signs of failure.

• Statistical-based predictive maintenance depends

on statistical data from the meticulous recording of
the stoppages of the in-plant items and components
in order to develop models for predicting failures.
• The drawback of predictive maintenance is that it
depends heavily on information and the correct
interpretation of the information.

• Some researchers classified predictive maintenance

as a type of preventive maintenance.

• The main difference between preventive

maintenance and predictive maintenance is that
predictive maintenance uses monitoring the
condition of machines or equipment to determine
the actual mean time to failure whereas preventive
maintenance depends on industrial average life
statistics.
 Types of Maintenance
MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

STATISTICAL CONDITION - DEFERRED REMEDIAL

ENGINEERING DESIGN - OUT
- BASED BASED
SERVICES

Shutdown Maintenance

WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN

NITY PREVENTIVE IMPROVEMENT CORRECTIVE

Figure 2.4 Maintenance Types